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Integrated control technology for the Karawanks Tunnel

Siemens is providing integrated control technology for the modernization of the Karawanks Tunnel. Combining automation, tunnel management, safety and cybersecurity, the solution supports safe, reliable and efficient operation of one of the key links between Austria and Slovenia.

Safely and traffic jam-free into the future

At nearly eight kilometers, the Karawanks Tunnel is Austria’s fourth-longest tunnel. Originally built as a single-tube route, it had become a major bottleneck, with more than 30,000 vehicles using it on peak days. For ASFINAG, Austria’s motorway operator, and construction partner STRABAG, the challenge was to build a second tube while modernizing tunnel operations and bringing the safety systems up to the latest technical standards. We're providing the control technology required for the safe and reliable operation of the tunnel infrastructure.

Peamised eelised

Maximum safety

Automated detection and integrated safety systems support rapid incident response.

Reliable operations

Centralized monitoring and control keep all tunnel systems working together.

Future-ready architecture

A standardized platform simplifies maintenance and accommodates future requirements.

Siemens technology from controllers to control room

Inside of a control cabinet

The project required an integrated automation solution spanning everything from the control level to the supervisory control system. At the core of the implementation are 50 redundant SIMATIC S7-1500H controllers and the WinCC Open Architecture supervisory control system. The system is configured in German and Slovenian to meet national requirements in Austria and Slovenia. More than 200 I/O modules were installed to connect and control the tunnel infrastructure, including lighting, ventilation and emergency call systems. The system architecture supports reliable operation while simplifying maintenance across the installation.

One key feature is the direct integration of the NTCIP (National Transportation Communications for ITS Protocol) into the SIMATIC controller. This simplifies the connection of several hundred warning traffic signs and helps streamline commissioning. Our solution also supports straightforward switching between the Austrian and Slovenian power grids.

Image of the tunnel tube showcasing the efficient integration of traffic signs using NTCIP
Our collaboration with Siemens was characterized by genuine teamwork and mutual trust. Siemens not only provided us with a durable control solution, but also worked proactively with us on innovations – such as the development of direct NTCIP protocol transmission within the control system. This close collaboration was a real asset and saved us a tremendous amount of time and money on the construction site.
Patrick Zwetti, Automation Technician, STRABAG

Focus on safety and cybersecurity

Cybersecurity was an integral part of the project from the outset. A closed system architecture certified in accordance with IEC 62443 was implemented for the Karawanks Tunnel. Encrypted communication helps protect data exchange, while the system architecture limits the spread of potential cyber incidents. This supports the secure operation of the critical tunnel infrastructure.

Illustration of a road tunnel highlighting three security layers: tunnel security, network security and system integrity.

Automated incident and fire detection

The solution also includes a video management and incident detection system with OPC UA (Open Platform Communications Unified Architecture) connectivity to the supervisory control system. 90 fixed cameras continuously monitor the tunnel and automatically detect incidents such as smoke, traffic disruptions, wrong-way drivers and stationary vehicles. The detected events are transmitted directly to the control center, enabling operators to respond without delay.

A highly available linear fire detection system provides continuous monitoring throughout both tunnel tubes as well as the operational and technical buildings. The system detects temperature changes at an early stage and supports rapid incident detection and response.

Real-world simulation for greater efficiency

A dedicated test environment played an important role in the successful implementation of the project. It enabled STRABAG Infrastructure & Safety Solutions to validate the complete control system before installation. This helped to identify and resolve potential issues early and reduce commissioning effort on site. We supported the project with engineering expertise and the development of project-specific solutions. Long-term spare parts availability and comprehensive lifecycle support help ensure the reliability and availability required for critical transport infrastructure.

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